Method and process to reduce surface cracking for coated hardwood composite flooring

ABSTRACT

The methods for making a coated thin veneer, plank or wood product in which the coated surface does not crack due to instability of the wood involve applying to a veneer, plank or wood product a composition including a hydrophilic polymer and a reactive monomer or a composition including a reactive (meth)acrylate. In one embodiment, the hydrophilic polymer is a polyalkylene glycol, such as polyethylene glycol. The composition also advantageously includes a thermally activated free radical initiator, a photoinitiator or both. The veneer is further laminated into wood product boards that are cut down to planks. In another aspect of the current invention, several solvent based resins are roll coated onto the loose and/or tight side of the thin veneer or unfinished plank wood, dried to remove solvent, and exposed to UV radiation to cure the resinous material by radical initiation of the photoinitiator that leads to polymerization. Further polymerization of the resin material within the pores or voids occurs by heat induced initiation of the organic peroxides at the time of lamination in the case of veneer or by UV radiation exposure in the case of planks.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This document claims priority to and the benefit of the filingdate of co-pending provisional application entitled “Method and Processto Reduce Surface Cracking for Coated Hardwood Composite Flooring,”assigned serial No. 60/388,419, and filed Mar. Jun. 13, 2002, which ishereby incorporated by reference.

FIELD OF THE INVENTION

[0002] This invention relates to a method for making a coated thinveneer, thicker plank and composite wood product wherein the coatedsurface does not crack due to instability of the wood composite and tothe coated veneer, plank and composite wood product.

BACKGROUND OF THE INVENTION

[0003] Wood composites such as plywood are used in many indoorapplications, in furniture and often in flooring applications. A majoradvantage of plywood over solid wood is that plywood does not warp, cupor twist, and does not swell or “move” as much as solid wood. However,there are many limitations to using plywood. The veneer used to coverthe individual plys is often very thin, and prone to delamination. Thecoatings must also be sufficient to protect the thin veneer fromscratching, because a scratch that goes through the thin veneer showsthrough to the underlying, less desirable inner plys. Also, water maycause swelling and buckling in plywood, as well as cracking. Thin veneercomposite wood products of the prior art often have a coated surfacethat cracks due to the instability of the wood composite.

[0004] Polyethylene glycol (PEG) has a high molecular weight and is notvery volatile. PEG has been used to treat wood by replacing the waterwith PEG, so that the passage of water in and out of the wood is nolonger possible. The wood is typically heated in a vat containing PEGfor an extended period of time to remove substantially all of the waterand replace it with PEG. This type of process is not typically performedon veneer. Rather, these methods are used to stabilize ‘green’ wood andrely on materials such as polyethylene glycol to enter the cell walls ofthe ‘green’ wood and improve dimensional stability. These methods havebeen previously published. See “New and Better Ways to DimensionallyStabilize Wood”, A J. Stam, Forest Products Journal, 9(1959):3, 107-110,and “Woodworker Heart,” Harry C. Leslie, Man Society Technology, AJournal of Industrial Arts Education, 33(1):13-16, September, October,1973. A limitation of these processes is that they tend to rely on longsoak times that are not typically practical for commercial production.

[0005] Veneer and planks have been impregnated with PEG andmethylmethacrylate using a vacuum process to harden the veneer andplanks. This batch process yields a product in which the concentrationof PEG and methylmethacrylate is substantially uniform throughout theveneer and plank.

[0006] It would be advantageous to have a continuous method for treatingveneer and planks using conventional coating apparatus, such that thetreated veneer and planks, and resulting coated wood composite, are notprone to cracking. Further, it would be advantageous to have such amethod, which minimizes the amount of treating material necessary todeter wood checking. The present invention provides such a method, andthe corresponding treated wood composite.

SUMMARY OF THE INVENTION

[0007] Methods for making a coated thin veneer composite wood productwherein the coated surface does not crack due to instability of the woodcomposite, and composite wood products prepared according to the methodare disclosed. The composites exhibit a dramatic reduction in crackingof the coating upon exposure to a modified version of the Hot/Coldchecking cycling ASTM D1211-97 test.

[0008] The methods involve applying a solution including (a) ahydrophilic polymer and a reactive monomer or (b) a (meth)acrylate to aveneer or plank. As used herein, the term “(meth)acrylate” means“acrylate, methacrylate, a combination of acrylate and methacrylate,acrylic, methacrylic, and a combination of acrylic and methacrylic.”

[0009] In one embodiment, the hydrophilic polymer is a polyalkyleneglycol, such as polyethylene glycol. In one embodiment, the reactivemonomer is a hexanediol diacrylate or hexanediol dimethacrylate. Thereactive monomer reacts in the presence of the hydrophilic polymerforming an interpenetrating polymer network.

[0010] The solution also advantageously includes a polymerizationinitiator, typically a thermally activated free radical initiator suchas azo-bisisobutyronitrile (AIBN) or peroxides such as benzoyl peroxide,dicumyl peroxide, t-butyl hydroperoxide, t-butyl perbenzoate, such thatthe coated veneer can be cured after the solution is applied to theveneer.

[0011] The veneer can be essentially any thickness between about{fraction (1/100)} inch and about ⅛ inch, but is most typically betweenabout {fraction (1/16)} and about {fraction (1/32)} inch in thickness.Although any type of wood can be used, the veneer is typically adecorative hardwood, such as oak, including Appalachian red oak,Appalachian white oak, Northern red oak, Northern white oak, cherry,walnut and the like, and the inner plys are typically a lesser gradewood, such as poplar. In one embodiment, the veneers have a thickness ofabout 170 mils and are formed from Appalachian oak, and the core ply hasa thickness of about 170 mils and is formed from poplar.

[0012] In one embodiment, the hydrophilic polymer is polyethyleneglycol, and the ratio of polyethylene glycol/reactive monomer/initiatoris about 49.5/49.5/1; the weight average molecular weight for thepolyethylene glycol is about 600; the reactive monomer is hexanedioldimethacrylate (HDDMA) and the initiator is azo-bisisobutyronitrile(AIBN).

[0013] In operation, a veneer board can be fed into a spread roll coaterthat applies the composition. The coated veneer board can then be heatedto a suitable temperature to partially cure the composition. The coreply is typically coated on one or both sides with a standard adhesive,for example, a water-based urea formaldehyde adhesive, and the treatedtop veneer and, optionally, bottom veneer are placed in contact with theappropriate surface of the adhesive coated core ply. The composite isthen consolidated under heat and pressure.

[0014] The resulting consolidated plywood panel is cut or sawed asneeded, for example, into flooring wood strips, which can then besubjected to routine operations, such as face sanding, staining andfinishing. Such processes are well known to those of skill in the art.

[0015] In one aspect of the current invention, a mixture of polyethyleneglycol and hexanediol dimethacrylate (HDDMA) with a radical initiatingcatalyst is roll coated (the method of application is not limited toroll coating but can include other coating methods, e.g., spray, curtaincoat, Mylar bar) onto both sides of a veneer, and oven processed toallow the resin to penetrate into the pores and voids, as well aspartially cure the resin material. The veneer is further laminated intowood product boards that are cut down to planks. Planks are furtherprocessed on the finishing line where stain, and several UV coatings areapplied to afford the final product.

[0016] In another aspect of the current invention, several solvent basedresins are roll coated onto the loose side and/or tight side of the thinveneer or unfinished plank wood (plank wood can be of solid or compositeconstruction), dried to remove solvent, and exposed to UV radiation tocure the resinous material by radical initiation of the photoinitiatorthat leads to polymerization. Further polymerization of the resinmaterial within the pores or voids occurs by heat-induced initiation ofthe organic peroxides at the time of lamination in the case of veneer orby UV radiation exposure in the case of planks. These resin materialsinclude a (meth)acrylate, which is polymerized in situ yielding apolymer reaction product.

[0017] In an additional embodiment, a (meth)acrylic containing solutionat least partially fills the pores and voids near the surface of thewood component. At least some of the solvent is driven off, drying thesolution.

[0018] As used herein “cured product” means the result of at leastpartially drying and/or partially curing the composition, which isapplied to the surface of the wood component. Unless the context wouldindicate otherwise, the composition may be the mixture of thehydrophilic polymer and reactive monomer, or the (meth)acrylate,including (meth)acrylic containing solutions.

DETAILED DESCRIPTION OF THE INVENTION

[0019] This invention relates to a method for improving the dimensionalstability of thin veneer wood and to prevent cracking of the coating ofa finished wood product by applying to the veneer or plank a resinmaterial that fills voids, lathe checks and spaces between grains.Further processing, followed by standard lamination, provides a coatedwood product. The end result is a treated wood veneer surface that whenprocessed into a finished wood product, such as a flooring product,exhibits a dramatic reduction in cracking of the coated surface (forexample, as determined by a modified version of the Hot/Cold cyclingASTM D1211-97 test).

[0020] The invention solves the problem currently known in the woodindustry as ‘checking’ on coated composite wood products—cracking of thecoating. The methods described provide multiple means to reduce crackingof the coated surface under conditions that cause “checking”. Theresulting wood composite products are typically of higher quality aschanges in environment will not cause undesirable cracks in the coatedproduct. This is particularly advantageous when the wood compositematerial is used in flooring operations, where several existing woodfloor manufacturers currently have issues associated with coatingcracking in installed wood floors.

[0021] The invention also offers a process and cost advantage overconventional process techniques such as vacuum impregnation asreferenced, for example, in U.S. Pat. Nos. 3,663,261, 5,605,915 and5,866,270. The methods allow for a continuous process that is compatiblewith existing wood composite operations, including wood flooringprocesses. Further, since the resin material, which is not subjected toa vacuum, remains concentrated near the surface of the veneer or plank,less of the resin material is necessary to deter checking.

[0022] In fact, since it is only capillary action that transports theresin material towards the center of the wood component, unless theveneer is very thin, the wood very soft or the wood has cracks thatpenetrate into the center portion of the wood component, the centerportion remains substantially free of the resin material and thereforesubstantially free of the resultant cured product. Even with thin, softand cracked wood, the concentration of the cured product near thesurface of the wood component is at least twice, or three times, or fivetimes, greater than the concentration at the center portion of the woodcomponent.

[0023] In another embodiment, the veneer surface is treated by treatingthe surface of a laminated veneer/core (plank). Accordingly, theinvention provides multiple, practical methods of solving a majorproblem of cracking of the coated surface of composite wood productsfrom seasonal changes and cycles.

[0024] Various aspects of the invention are described in more detailbelow:

[0025] I. Coating Compositions

[0026] In one embodiment, the coating compositions used to coat theveneer as described herein typically include at least one hydrophilicpolymer, at least one reactive monomer, and at least one thermalinitiator. The ranges of hydrophilic polymer and the reactive monomerare each typically between about 30 and about 70 percent by weight ofthe composition, more typically between about 40 and about 60 percent byweight of the composition. The range of thermal initiator in thecomposition is typically between about 0.5 and about 10 percent byweight of the composition. Most typically it is about 1% of thecomposition.

[0027] The types of chemistries demonstrated in this invention includehydrophilic polymer/reactive monomer mixtures such as polyethyleneglycol/(meth)acrylate mixtures and polyethyleneglycol/water/(meth)acrylate mixtures, and reactive monomers can includeurethane (meth)acrylates, multifunctional (meth)acrylates, polyester(meth)acrylates, and other reactive monomers described in more detailbelow. Urethane (meth)acrylate and multifunctional (meth)acrylatesolutions, suspensions or dispersions can also be used, alone or incombination with the hydrophilic polymer/reactive monomer mixture.

[0028] Hydrophilic polymers

[0029] Any hydrophilic polymer that can penetrate wood and stabilize thewood to water permeation can be used. Examples of suitable hydrophilicpolymers include polyethylene glycol and pentracryl.

[0030] When the hydrophilic polymer is polyethylene glycol, the weightaverage molecular weight is typically between about 400 and about 1000.The molecular weight can be selected so that the polyethylene glycol isliquid at the temperature at which it is applied to the veneer. If theveneer is at room temperature when the polyethylene glycol is applied,then the molecular weight is typically less than about 1000, moretypically about 550 to about 650.

[0031] The hydrophilic polymer can typically be present from about 30wt. % to about 70 wt. %. Depending on the desired properties of theveneer (thickness, wood type, etc.) and the molecular weight andfunctionality of the reactive monomer, values outside this range arepossible. Those of skill in the art can readily optimize theconcentration of the hydrophilic polymer and the reactive monomer.

[0032] In some embodiments, water may be added to the hydrophilicpolymer.

[0033] Reactive Monomers

[0034] A reactive monomer system is used in combination with thehydrophilic polymer to penetrate the wood and prevent cracking. Suitablereactive monomer systems include at least one ethylenically unsaturatedaddition-polymerizable monomer which is polymerizable upon exposure to asource of free radicals and/or radiation such as UV or EB radiation, or,alternatively, to heat, depending on the type of free radical initiator.Specific examples of reactive monomers that can be used include UVcurable resin materials derived from ester acrylates, such as hexanedioldimethacrylate, urethane acrylates, isocyanate terminated urethaneacrylates, water-based urethanes and acrylic polymers.

[0035] The monomer can include acrylate or methacrylate unsaturation, aswell as other types of monomer that include non-(meth)acrylate vinylunsaturation. The reactive monomer system can include mono-, di-, tri-,and higher functional monomers. The number average molecular weight ofthe monomer is typically low enough to allow it to be a liquid at roomtemperature, and in general, is less than about 1,000 g/mol. Mixtures ofmonomers can be used.

[0036] Examples of the monofunctional reactive monomers include2-hydroxyethyl(meth)acrylate, isobornyl acrylate (IBOA), phenoxyethylacrylate, isodecyl acrylate, hexyl acrylate, cyclohexyl acrylate,2-ethylhexyl acrylate, octyl acrylate, nonyl acrylate, stearyl acrylate,2-phenoxy acrylate, 2-methoxyethyl acrylate, lactone modified esters ofacrylic and methacrylic acid, methyl methacrylate, butyl acrylate,isobutyl acrylate, methacrylamide, allyl acrylate, tetrahydrofurylacrylate, n-hexyl methacrylate, 2-(2-ethoxy-ethoxy)ethyl acrylate,n-lauryl acrylate, 2-phenoxyethyl acrylate, glycidyl methacrylate,glycidyl acrylate, acrylated methylolmelamine, and2-(N,N-diethylamino)-ethyl acrylate.

[0037] Examples of polyfunctional reactive monomers include neopentylglycol diacrylate, alkoxylated neopentyl glycol diacrylate, ethyleneglycol diacrylate, hexylene glycol diacrylate, diethylene glycoldiacrylate, tripropylene glycol diacrylate, tetraethylene glycoldiacrylate, pentaerythritol di-, tri-, tetra-, or penta-acrylate,trimethylolpropane triacrylate, alkoxylated trimethylolpropanetriacrylate which contains from about 2 to about 20 moles of eitherethylene or propylene oxide, triethylene glycol diacrylate,tetraethylene glycol diacrylate, polyethylene glycol diacrylate, anycorresponding methacrylates thereof, and combinations thereof.

[0038] Examples of non-(meth)acrylate reactive monomers include vinyl,N-vinyl, vinyl-ether, vinylester and allyl groups. Suitable examples ofthis type of reactive monomer include N-vinylformamide (NVF), adducts ofNVF with diisocyanates such as toluene diisocyanate and isophoronediisocyanate, derivatives of N-vinylformamide, N-vinylcaprolactam,N-vinylpyrrolidone, butyl-vinylether, 1,4-butyl-divinylether,dipropyleneglycol-divinylether, the vinylester of acetic acid, laurylacid, dodecanoic acid or cyclohexylcarboxylic acid, adipic acid,glutaric acid or the like, triallylisocyanurate, diallylphthalate,butyl-allyl-ether and the like. In one embodiment, the monomers aredi-functional.

[0039] The reactive monomer can be present from about 30 wt. % to about70 wt. %. Depending on the desired properties of the veneer (thickness,wood type, etc.) and the molecular weight of the hydrophilic polymer,values outside this range are possible. Those of skill in the art canreadily optimize the concentration of the hydrophilic polymer and thereactive monomer.

[0040] Thermal Initiator

[0041] Thermal initiators such as azo-bisisobutyronitrile (AIBN) orperoxides such as benzoyl peroxide, dicumyl peroxide, t-butylhydroperoxide, and t-butyl perbenzoate are well known and are availablefrom common chemical suppliers. The thermal initiator is present in anamount sufficient to at least partially cure the reactive monomer whenheat is applied to a veneer coated with the composition. The amounttypically ranges from about 0.5 to about 10 wt. % by weight of thecomposition. Typically, about 1% is used.

[0042] Photoinitiator

[0043] In some embodiments, it may be desirable to use a photoinitiatorin place of or in addition to the thermal initiators. Thephotoinitiators can catalyze or accelerate cure by exposure toultraviolet radiation. If the polymerizable material is cured byexposure to electron beam radiation, a photoinitiator is not typicallyused.

[0044] The photoinitiator can be any of the known photoinitiators suchas benzophenone, benzoin, acetophenone, benzoin methyl ether, Michler'sketone, benzoin butyl ether, xanthone, thioxanthone, propiophenone,fluorenone, carbazole, diethoxyacetophenone, the 2-, 3- and4-methylacetophenones and methoxy-acetophenones, the 2- and3-chloroxanthones and chlorothioxanthones, 2-acetyl-4-methylphenylacetate, 2,2′-dimethoxy-2-phenylacetophenone, benzaldehyde, fluorene,anthraquinone, triphenylamine, 3- and 4-allyl-acetophenone,p-diacetylbenzene, 3-chloro-2-nonylxanthone, 2-chlorobenzophenone,4-methoxybenzophenone, 2,2′,4,4′-tetrachlorobenzophenone,2-chloro-4′-methylbenzophenone, 4-chloro-4′-methylbenzophenone,3-methylbenzophenone, 4-tert-butylbenzophenone, isobutyl ether-benzoicacetate, benzil, benzilic acid, amino benzoate, methyl blue,2,2-diethoxyacetophenone, 9,10-phenanthrenequinone, 2-methylanthraquinone, 2-ethyl anthraquinone, 1-tert-butylanthraquinone,1,4-naphthaquinone, isopropylthioxanthone, 2-isopropylthioxanthone,2-methylthioxanthone, 2-decylthioxanthone, 2-dodecylthioxanthone,2-methyl-1, [4-(methylthio)phenyl]-2-morpholinopropanone-1, combinationsthereof and the like.

[0045] The optional photoinitiator or combination of photoinitiators istypically used in an amount ranging from about 1 to about 10 wt. % byweight of the composition.

[0046] II. Composite Wood Core

[0047] The composite wood core can have virtually any number of plys,but typically has between 1 and 20 plys, more typically, 1, 3, 5, 7 or 9plys. The plys are typically a relatively inexpensive, butadvantageously dimensionally stable, wood such as poplar. In theindustry, plywood is typically available in a variety of thicknesses,ranging from ⅛ to 1 inch, and is more typically ⅜, ½ or ¾ inch material.The thickness is generally determined by the number of individual plys,including the outer veneer layer or layers.

[0048] In some embodiments, it is not necessary to have a decorativeveneer on both sides. This is particularly true when one face is neverseen, for example, in flooring operations where one face is seen and theother is attached to or at least placed over a subfloor. However, veneerflooring often includes veneer on both faces so that the best matchbetween adjacent flooring strips can be obtained.

[0049] In some embodiments, the veneer is not applied to a plywood core,but rather, to a particle board, medium density fiberboard, chipboard,solid wood or other suitable core.

[0050] III. Methods of Applying the Coating Composition to Veneer

[0051] The coating composition can be applied to the veneer to be coatedby conventional methods such as by roll coating, spraying, dipping, orpassing the substrate through a Kiss roll applicator as is known in theart. Other methods for coating substrates with top coat compositionsknown in the art can also be used.

[0052] If additional penetration of coating composition is desired thecomposition, veneer or both can be preheated. Heating the coatingcomposition reduces viscosity and heating the veneer is believed to openthe grain and pores in the wood.

[0053] IV. Methods of Curing the Treated Veneer

[0054] Typically, the coated veneer is intended to be only partiallycured before it is applied to the core ply material, although it can becompletely cured in some embodiments, particularly where the coating isapplied to the veneer/core plywood material. The degree of partial cureis typically below 60%. The degree of cure can be controlled byadjusting the temperature and time at which the coated veneer is heated.These reaction conditions will have to be adjusted depending on thethickness of the veneer, the desired degree of cure, and the types andratios of the components in the coating composition, particularly therelative amount of the thermal initiator. However, those of skill in theart can readily determine appropriate reaction conditions to arrive at adesired level of cure. Further, the amount of resin material that wickedinto the open pores, and grain structure can be optimized by controllingthe relative ratios of the individual components of the coatingcomposition, the reaction temperature, roll pressures and reaction timesused in this process.

[0055] V. Methods of Applying the Cured Veneer to Inner Plys

[0056] Once the veneer is coated and partially cured, it can be appliedto the top and, optionally the bottom, of a plywood core. Any suitableadhesive can be used to adhere the partially-cured veneer and theplywood core. In one embodiment, the adhesive is a urea-based adhesivesuch as known to those in the veneering art.

[0057] After the veneer is applied to the core ply, the material iscured by application of heat and/or pressure for a suitable amount oftime. Typically, the temperature ranges from between about 200° F. andabout 350° F., the pressure ranges from between about 100 and about 250psi, and the time ranges from between about 2 and about 5 minutes.Conditions outside these ranges can be employed.

[0058] VI. Methods for Processing the Resulting Plywood

[0059] After the plywood has been prepared, it can be processed usingconventional steps, such as but not limited to sawing to appropriatesize, sanding, staining and finishing. When used as flooring, theplywood is typically cut into lengths of between about 2 and about 8feet, and widths of between about 2 and about 6 inches, although lengthsand widths outside of these ranges are acceptable. Methods forperforming these standard operations are typically no different thanthey are for conventional plywood.

[0060] VII. Additional Aspect—Improving the Dimensional Stability ofThin Wood Veneer

[0061] Another aspect of this invention relates to a method forimproving the dimensional stability of thin veneer wood to preventcracking in the coated surface by applying a diluted resin material intothe voids, lathe checks, and between grains and further removing thesolvent followed by curing the resin material by UV and/or by thermalcure. The UV curing can be accomplished by incorporating any of thephotoinitiators described into the coating composition.

[0062] In one embodiment, Northern or Appalachian thin veneer sheets(although other veneer sheets can be used) are treated with a monomerpolyethylene glycol/acrylate mixture containing an azo free radicalcatalyst (catalyst containing a N═N group,) where the mixture has arelatively low viscosity, which allows the resin material to wickthrough the veneer and fill the lathe checks, open voids and otherchannels parallel to the grains.

[0063] The treated veneer can be passed through a gas-fired oven toallow deeper penetration of the resin material and partially cure theresin material. Further heat treatment by lamination finishes the cure.

[0064] Similarly, veneer can be treated with radiation curable resins ina suitable, typically volatile, solvent thereby allowing the resinousmaterial to wick through the veneer and fill the lathe checks, openvoids and other channels parallel to the grains. The resinous materialcan be cured by a dual cure process involving both heat and UV-activatedfree radical initiators. In this embodiment, upon exposure to UVradiation, where the UV-photoinitiator catalyzes cure at the veneersurface, the initial heat of polymerization and IR from UV lamps yieldsenough heat to activate peroxide cure of part of the remainder of theresin material within the voids and pores. Further heat treatment duringlamination of the veneer boards to form the final multi-ply productfinishes off the cure of the resinous material in the pores and lathechecks. The end result yields an insoluble material in the lathe checks,open voids and other channels parallel to the grains. Moisture diffusioninto the wood is now limited and therefore the common mechanisms ofexpansion and contraction of the wood due to uptake or loss of waterwithin the cell are deterred.

[0065] VIII. Additional Aspect—Treating Solid & Composite Wood PlanksWith 100% Solids Compositions

[0066] Another aspect of this invention uses 100% solids UV curableresinous materials including the reactive monomers described above, suchas multi-functional acrylates, urethane acrylates, cellulose acrylatederivatives, and combinations thereof. These materials are roll coatedonto unfinished plank wood (plank wood can be of solid or compositeconstruction) and UV cured. These compositions also advantageouslyinclude a photoinitiator such as those described above. The treated woodis subsequently processed on the finishing line.

[0067] The present invention will be better understood with reference tothe following non-limiting examples. Each of examples 1-7 use thefollowing “Modified Cycle Testing for Wood/Finish Cracking based on ASTMD1211” to evaluate performance characteristics of the finished products.

[0068] This test method can be used to determine the resistance tochecking and cracking of cured coating applied to wood or plywoodsubstrates when subjected to sudden changes in temperature and moisturefrom hot to cold, which is considered one cycle. The test distinguishesbetween cycles to initial checking or cracking and cycles to finalfailure. This test is designed to accelerate the appearance of checks orcracks in final finished coated wood product. A summary of results forExamples 1-7 is given in Table 1, following Example 7.

[0069] All samples are to be 3″×15″. Various grain patterns are selectedfor testing to obtain more representative results. When possible atleast 10 pieces of a particular test are run for better representationof the sample.

[0070] 1. Place the samples in an oven at 120° F. for 1 hour.

[0071] 2. Immediately place the samples in a freezer set at −5° F. Thesamples are to remain in the freezer for 1 hour. The samples need to bemoved from the oven to the freezer in less than 5 minutes.

[0072] 3. Remove the samples from the freezer and place them on a labbench at room temperature (75+/−3° F.) for 15 minutes.

[0073] 4. Visually check the samples for any checks or cracks formed inthe finish from the cycle.

[0074] Steps 1-4 are repeated until a total of 10 cycles are complete.

[0075] Evaluation of cracks and reporting data:

[0076] All cracks are marked at each end of the crack and labeled as tothe cycle they occurred.

[0077] Cracks propagating within ½″ of the ends of the board are notcounted.

[0078] A sample fails when:

[0079] a) there are 12 cracks with a length over ⅜″ long on the sample;

[0080] b) there are 4 cracks over 1″ long on the sample; or

[0081] c) there are 2 cracks over 2″ long on the sample.

[0082] The overall appearance is judged as no cracking, slight cracking,moderate cracking, or severe cracking after all ten cycles arecompleted.

[0083] Examples 1-7 in Table 1 illustrate the usefulness of the presentinvention.

EXAMPLES FOR WOOD VENEER AND PLANK WOOD STABILIZATION TO PREVENT SURFACECHECKING

[0084] The following examples are broken down into two categories ofveneer-treated examples and plank-finished examples where the veneer inmost cases is considered thick (⅙ inch).

Example 1 Monomer Acrylate/PEG to Stabilize ⅙ Inch Appalachian OakVeneer

[0085] A coating composition was prepared as follows to have a roomtemperature viscosity (77° F.) of 30 cps. HDDMA(Sartomer SR239) 49.5 gPolyethyleneglycol (PEG 600) 49.5 g Vazo 67 catalyst (3M)  1.0 g

[0086] This composition was applied via roll coater onto both sides of a4 ft×4 ft×⅙ inch Appalachian Oak Veneer face at a total applicationweight of 10 gms/sq ft (5 gms sq/ft per side of veneer). The veneersample was then further processed through a gas-fired oven set at 170°F. for a period of 2.3 minutes. At this stage, the monomer/PEG blend wasonly partially cured as noted by a slight oily surface when the surfacewas warm. Planks were then laminated into 3 ply product at a temperatureof 260° F. for 5.5 minutes. During this time frame, the monomer/PEGfully cured within the grain structure of the wood. The composite woodboard, comprised of ⅙ veneer face, ⅙ inch core Poplar, Oak or Gum, and ⅙inch veneer face, was then cut into 3″ wide tongue and groove woodflooring, although the invention is not limited to any specific width.The flooring was then coated with existing finish coatings to give thefinal aesthetics. Ten samples of wood flooring were tested by a modifiedversion of the ASTM D1211-97 test. Results are given in Table 1.

Example 2 Sprayed Urethane Acrylate/Isopropanol to Stabilize {fraction(1/12)} Inch Appalachian Oak Veneer

[0087] A coating composition was prepared as follows: Urethane acrylate(Bayer trade name) UAUPLS 2337 1678.3 g Isopropanol 1200.0 gPhotoinitiator (Ciba, Irigacure 819) 8.4 g Photoinitiator (LambertiEsacure KIP 100F) 67.1 g Photoinitiator (Benzophenone) 16.8 gCo-initiator (Sartomer CN371) 33.6 g Methylethyl Ketone 350.0 gSurfactant, (Silwet L-7200) 16.8 g Lupersol 575M75 (Atofina) 0.08 g

[0088] The coating was sprayed on the loose side and the tight side of{fraction (1/12)} inch Appalachian Oak veneer using a Divilbus spray gunequipped with a pressure pot, 12-15 psi fluid pressure, 45 psi onatomization. Estimated film thickness was 3-7 mils wet. Samples wereallowed to air dry and passed through the UV oven twice at 528 mJ/cm²per pass for a total of about 1.0 Joule/cm². UV cured veneer sampleswere stiffer after cure indicating that acrylate polymerizationoccurred. Veneer boards were then laminated (tight side up) as the topboard of a five ply construction at 260° F. for 5 minutes at 180 psi.These boards were cut into flooring planks and subsequently processed onthe coating finishing line. Ten samples of wood flooring were tested bythe modified version of the ASTM D1211-97 test.

Example 3 Treatment of Unfinished 3 Ply Plank With ⅙ Inch AppalachianOak Veneer Face

[0089] A water-based sealer composition was prepared as follows:Carboset CR716 acrylic 67.3 g Sancure 815 polyurethane dispersion (BFG)15.0 g Triethylamine 0.1 g NXZ defoamer 0.3 g Glycol PM propylene glycolmonomethylether 5.0 g Glycol EB butyl cellusolve 5.0 g Triton GR SM(Triton Surfinyl) 0.3 g

[0090] This formulation was roll coated onto unfinished 3 plyconstruction Appalachian Oak planks (4.4 gms/sq ft.) consisting of a topand bottom oak veneer layer with a center poplar layer. Samples werepassed through a convention and IR fired oven to remove the water.Samples were then sanded and finished samples of wood flooring weretested by the modified version of the ASTM D1211-97 test. Results aregiven in Table 1.

Example 4 Treatment of Unfinished 3 Ply Plank With ⅙ Inch AppalachianOak Veneer Face

[0091] The coating composition described in Example 2 was prepared andapplied onto 3 ply Appalachian Oak planks (5.8 g/sq. ft) andsubsequently passed through an IR oven to remove the solvent. Sampleswere then lightly sanded and processed on the UV coating finishing line.Final cure of the sealer composition was achieved through a combinationof subsequent UV exposure to initiate radical polymerization and IR heatto promote thermal cure.

Example 5 Treatment of Unfinished 3 Ply Plank With ⅙ Inch AppalachianOak Veneer Face

[0092] A coating composition was prepared as follows: Dipentaerythritolpentacrylate (Sartomer SR399) 9382.6 g Photoinitiator (Ciba, Irgacure184) 186.7 g Photoinitiator (Benzophenone) 374.6 g Co-initiator(Sartomer CN371) 37.3 g Surfactant (Dow DC193) 34.8 g Lubosol 575M75(Atofina) 18.7 g

[0093] The composition was applied onto 3 ply Appalachian Oak veneerplanks (9.8 gms/sq. ft) using a three roll coater. The plank temperaturewas increased to 155° F. and a three roll coater was used to optimizethe amount of penetration into the wood. The conditions were as follows:Doctor roll (ceramic, clockwise) 1.9 fpm, Applicator roll (rubberdurometer 35-40, clockwise) 55 fpm, wiper roll (48 fpm, chrome, counterclockwise) and line speed was 48 fpm.

[0094] This worked well because the applicator roll was moving fasterthan the line speed, the pressure from running faster creates an excessof material behind the applicator roll that flooded in-between the rolland the veneer thereby optimized the amount of resin material into theveneer. The wiper roll drove excess resin into the veneer voids andpores and removed the excess resin. This process gave a saturated buildwithout any excess resin on the surface to affect other parameters downthe line, such as adhesion of coating to veneer. If a three roll coaterarrangement had not been used, excess coating might have remained on thesurface and not be driven into the veneer and therefore affected thefinal ultimate performance of the final wood product. Also, if excessresin material were not removed, it might have caused possibledelamination between layers in the case when the resin material is rollcoated on both sides, or caused possible coating-to-veneer adhesionproblems.

[0095] The coated and cured composite was lightly sanded and processedon the UV coating finishing line where stain, seal, mineral and topcoatswere applied and UV cured. Final cure of the applied inventivecomposition was achieved through a combination of subsequent UV exposureto initiate radical polymerization and IR heat to promote thermal cure.

Example 6 UV Stain With Additive to Prevent Checking on 3 Ply ⅙ InchAppalachian Oak Veneer

[0096] A UV stain composition was prepared as follows: Akzo UV Stain(Mink) 2155.3 g NCO bearing aliphatic urethane acrylate 1258.7 g (Bayertrade name) UAUPLS 2337 Photoinitiator (Ciba, Irgacure 819) 6.3 gPhotoinitiator (Lamberti Esacure KIP 100F) 50.3 g Photoinitiator(Benzophenone) 12.6 g Co-initiator (Sartomer CN371) 25.2 g Surfactant(Silwet L-7200) 12.6 g Lubosol 575M75 (Atofina) 0.6 g

[0097] The stain composition was applied onto 3 ply Appalachian Oakveneer planks (9.8 gms/sq. ft) using a three roll coater. To optimizethe amount of penetration of the resin material into the wood, theparameters used were: doctor roll (10.6 fpm clockwise), applicator roll(72 fpm, clockwise), wiper roll (60 fpm counterclockwise), and linespeed 60 fpm. The coated planks were processed on the UV finishing linewhere seal, mineral and topcoats were applied and UV cured. Final cureof the applied inventive composition was achieved through a combinationof subsequent UV exposure to initiate radical polymerization and IR heatto promote thermal cure.

Example 7 UV Stain With Additive to Prevent Checking on 3 Ply ⅙ InchAppalachian Oak Veneer

[0098] A UV stain composition was prepared as follows: Akzo UV Stain(Mink) 2272.0 g Urethane acrylate (Bayer trade name) UAUPLS 2258 454.4 gUrethane acrylate (Bayer trade name) UAUPLS 2265 681.6 g Photoinitiator(Ciba, Irgacure 819) 5.7 g Photoinitiator (Lamberti Esacure KIP 100F)45.4 g Photoinitiator (Benzophenone) 11.4 g Co-initiator (SartomerCN371) 22.7 g Surfactant (Silwet L-7200) 11.4 g Lubosol 575M75 (Atofina)0.6 g

[0099] Similar to Example 4, the stain composition was added appliedonto 3 ply Appalachian Oak veneer planks (9.8 gms/sq. ft) and processedon the UV finishing line where stain, seal, mineral and topcoats wereapplied and UV cured. Final cure of the applied inventive compositionwas achieved through a combination of subsequent UV exposure to initiateradical polymerization and IR heat to promote thermal cure.

Example 8 Treatment of Unfinished 5 Ply Plank With {fraction (1/10)}Inch Northern Oak Veneer Face

[0100] The water-based sealer composition of Example 3 was roll coatedonto unfinished 5 ply construction Northern Oak planks, processed andtested in a manner similar to Example 3. Results of the control andExample 8 are given in Table 1.

Example 9 Treatment of Unfinished 5 Ply Plank With ⅜ Inch Northern OakVeneer Face

[0101] A water-based sealer composition of similar to Example 3, butwith 20% by weight of PEG 600 was hand applied onto unfinished 5 plyconstruction Northern Oak planks, processed and tested in a mannersimilar to Example 3. The application rate was about 4.5 to about 5grams/sq ft. Results of the control and Example 9 are given in Table 1.

Examples 10 to 12 Sprayed Coating Compositions to Stabilize {fraction(1/12)} Inch Northern Oak Veneer

[0102] The following coating compositions were applied onto unfinished 5ply construction Northern Oak planks, processed and tested in a mannersimilar to Example 2. Results of the control and Examples 10 to 12 aregiven in Table 1.

Example 10

[0103] A coating composition was prepared as follows: Dipentaerythritolpentacrylate (Sartomer SR399) 2714.0 g Isopropanol 2714.0 Photoinitiator(Ciba, Irgacure 184) 54.3 g Photoinitiator (Benzophenone) 108.6 gMethylethyl Ketone 1392.8 g Surfactant (Silwet L-7200) 10.9 g Lubosol575M75 (Atofina) 5.4 g

Example 11

[0104] A coating composition was prepared as follows: Urethane acrylate(Sartomer CN133) 862.3 g Dipentaerythritol pentacrylate (Sartomer SR399)287.4 g Propoxylated HDDA (Sartomer CD564) 1724.5 g Photoinitiator(Ciba, Irgacure 819) 14.4 g Photoinitiator (Lamberti Esacure KIP 100F)115.0 g Photoinitiator (Benzophenone) 28.7 g Co-initiator (SartomerCN371) 57.5 g Methylethyl Ketone 3880.1 g Surfactant, (Silwet L-7200)28.7 g Lupersol 575M75 (Atofina) 1.4 g

Example 12

[0105] A coating composition was prepared as follows:Di-trimethyolpropane tetraacrylate (Sartomer SR355) 2157.7 g Isopropanol2157.7 g Photoinitiator (Ciba, Irgacure 819) 8.6 g Photoinitiator(Lamberti Esacure KIP 100F) 86.3 g Photoinitiator (Benzophenone) 43.15 gCo-initiator (Sartomer CN371) 43.15 g Methylethyl Ketone 2502.9 gSurfactant, (Silwet L-7200) 8.6 g Lupersol 575M75 (Atofina) 0.4 g

Examples 13 to 15 Monomer Acrylate/PEG to Stabilize {fraction (1/12)}Inch Oak Veneer

[0106] A coating composition similar to Example 1 was prepared andapplied onto unfinished {fraction (1/12)} inch 5 ply constructionAppalachian, Northern and Southern Oak planks, processed and tested in amanner similar to Example 1. Results of the controls and Examples 13 to15 are given in Table 1. Fifteen samples and controls were used for theAppalachian and Northern Oaks; 22 samples and controls were used for theSouthern Oak. TABLE 1 Summary of Examples Cycles to # of Plys Cycles toFirst Failure Application Board Type Laminated Crack (avg. of (avg. ofEx # Rate (g/ft2) Veneer/plank Product 10 samples) 10 samples) ControlNone ⅙ inch 3 ply 3 4.7 Appalachian  1 5 ⅙ inch 3 ply 7.5 10.1Appalachian  2 Sprayed ⅙ inch 5 ply 9.7 10.8 Appalachian  3 4.4 ⅙ inch 3ply 5.8 10.6 Appalachian unfinished plank  4 5.8 ⅙ inch 3 ply 8 10.8Appalachian unfinished plank  5 9.8 ⅙ inch 3 ply 6.8 10.6 Appalachianunfinished plank  6 9.8 ⅙ inch 3 ply 4.9 9.4 Appalachian unfinishedplank  7 9.8 ⅙ inch 3 ply 8.8 10.7 Appalachian unfinished plank ControlNone {fraction (1/10)} inch 5 ply 2.7 5.9 Northern  8 4.4 {fraction(1/10)} inch 5 ply 4.5 7.1 Northern Control None ⅜ inch 5 ply 3.4 6.4Northern  9 4.5-5 ⅜ inch 5 ply 4.8 7.2 Northern Control None {fraction(1/12)} inch 5 ply — 6.9 Northern 10 Sprayed {fraction (1/12)} inch 5ply 6.8 9.1 Northern 11 Sprayed {fraction (1/12)} inch 5 ply 6.1 9.2Northern 12 Sprayed {fraction (1/12)} inch 5 ply 5.2 8.1 NorthernControl 5 {fraction (1/12)} inch 5 ply 4.0 7.0 Appalachian 13 5{fraction (1/12)} inch 5 ply 4.9 8.5 Appalachian Control 5 {fraction(1/12)} inch 5 ply 4.7 7.7 Northern 14 5 {fraction (1/12)} inch 5 ply4.7 8.7 Northern Control 5 {fraction (1/12)} inch 5 ply 6.6 9.3 Southern15 5 {fraction (1/12)} inch 5 ply 9.7 11 Southern

[0107] Example 1 was coated with monomer acrylate/PEG by roll coatingboth sides.

[0108] Example 2 was coated with LS2337 urethane acrylate by sprayingthe loose and tight side.

[0109] Example 3 was coated with CR716 acrylic by roll coating.

[0110] Example 4 was coated with LS2337 urethane acrylate by rollcoating.

[0111] Example 5 was coated with SR399 dipentaerythritol pentacrylate byroll coating.

[0112] Example 6 was coated with LS2337 urethane acrylate by rollcoating.

[0113] Example 7 was coated with Stain Additive: LS2258 and LS2265 byroll coating.

[0114] Example 8 was coated with CR716 acrylic by roll coating.

[0115] Example 9 was coated with CR716 acrylic by hand application.

[0116] Example 10 was coated with SR399 dipentaerythritol pentacrylateby spraying.

[0117] Example 11 was coated with CN133 urethane acrylate, SR399dipentaerythritol pentacrylate and CD564 propoxylated HDDA by spraying.

[0118] Example 12 was coated with SR355 di-trimethyolpropanetetraacrylate by spraying.

[0119] Examples 13 to 15 were coated with monomer acrylate/PEG by rollcoating both sides.

[0120] As shown in the Examples, less than 20 grams/sq ft of the resinmaterial is applied to the wood component, and therefore the componentcomprises less than 20 grams/sq ft of the cured product. In some cases,less than 15 grams/sq ft of the resin material is applied, and in othercases, less than 12 grams/sq ft of the resin material is applied. Whenthe vacuum impregnation process of the prior art is used, about 28% toabout 30% by weight of an oak component is impregnated into the oakcomponent. Maple absorbs about 50% by weight the of resin material inthe prior art vacuum process, and basswood absorbs about 120% to about150% by weight of the resin material.

[0121] Having disclosed the subject matter of the present invention, itshould be apparent that many modifications, substitutions and variationsof the present invention are possible in light thereof. It is to beunderstood that the present invention can be practiced other than asspecifically described. Such modifications, substitutions and variationsare intended to be within the scope of the present application.

What is claimed is:
 1. A process for producing a wood productcomprising: selecting a wood component selected from the groupconsisting of a veneer and a plank, the wood component having a firstmajor surface and a second opposed major surface; applying a compositionto the first surface of the wood component; and then performing afurther step selected from the group consisting of drying, at leastpartially curing, and a combination thereof; whereby the compositionpenetrates a portion of the wood component adjacent the first surface;the composition comprising a component selected from the groupconsisting of (a) a mixture of a hydrophilic polymer and a reactivemonomer, and (b) a (meth)acrylate; the (meth)acrylate being selectedfrom the group consisting of a urethane (meth)acrylate, amultifunctional (meth)acrylate and combinations thereof; the woodcomponent being subjected to no less ambient pressure from the time thecomposition is applied to the first surface until the further step isperformed.
 2. The process of claim 1, wherein the composition furthercomprises a free radical initiator.
 3. The process of claim 2, whereinthe initiator is selected from the group consisting of thermalinitiators, photoinitiators and combinations thereof.
 4. The process ofclaim 3, wherein the composition comprises a thermal initiator and aphotoinitiator, the composition being subjected to both heat andradiation to at least partially cure the composition.
 5. The process ofclaim 1, wherein the portion of the wood component adjacent the secondsurface is substantially free of the composition.
 6. The process ofclaim 1, wherein the composition further comprises a staining agent. 7.The process of claim 1, wherein the second surface of the wood componentis laminated to another layer.
 8. The process of claim 7, wherein thesecond surface of the wood component is laminated to the another layerprior to applying the composition to the wood component.
 9. The processof claim 1, further comprising applying and curing a high performancetop coat onto the first surface after the composition is dried or atleast partially cured.
 10. The process of claim 1, further comprisingapplying a coat selected from the group consisting of a stain coat, afill coat, and a combination thereof to the first surface.
 11. Theprocess of claim 1, wherein a three roll coater is used to apply thecomposition to the first surface, the three roll coater comprising adoctor roll, an applicator roll and a wiper roll, the ratio of thesurface speed of doctor roll to the surface speed of the applicator rollbeing at least 1:5 and no more than 1:20, the wiper roll rotating in theopposite direction of the applicator roll, the ratio of the surfacespeed of the applicator roll to the surface speed of the wiper rollbeing at least 1:1.
 12. The process of claim 1, wherein the hydrophilicpolymer is polyethylene glycol and the reactive monomer is hexanedioldimethacrylate.
 13. The process of claim 1, wherein the urethane(meth)acrylate is an isocyanate terminated urethane (meth)acrylate. 14.The process of claim 1, wherein the urethane (meth)acrylate or themultifunctional (meth)acrylate is a dispersion.
 15. The process of claim1, wherein the hydrophilic polymer comprises polyethylene glycol (PEG)having a weight average molecular weight between about 200 and about2000.
 16. The process of claim 1, wherein the composition comprises amixture of PEG and a multifunctional acrylate monomer.
 17. The processof claim 1, wherein the composition comprises an aliphatic urethane(meth)acrylate that reacts with free water or cellulose to form amoisture barrier.
 18. The process of claim 1, wherein the compositionfurther comprises a second reactive monomer.
 19. The process of claim18, wherein the (meth)acrylate is a urethane (meth)acrylate and thesecond reactive monomer is a different (meth)acrylate.
 20. The processof claim 3, wherein the thermally activated free radical initiator is anazo or peroxide-derived thermally activated free radical initiator. 21.The process of claim 1, wherein the reactive monomer comprises analiphatic urethane terminated with a moiety selected from the groupconsisting of a (meth)acrylate group, a free isocyanate group, andcombinations thereof.
 22. The process of claim 1, wherein the woodcomponent is heated prior to the application of the composition.
 23. Aprocess for producing a wood product comprising: selecting a woodcomponent selected from the group consisting of a veneer and a plank,the wood component having a first major surface and a second opposedmajor surface; applying a composition to the first surface of the woodcomponent; and then performing a further step selected from the groupconsisting of drying, at least partially curing, and a combinationthereof; whereby the composition penetrates a portion of the woodcomponent adjacent the first surface; the composition comprising a(meth)acrylate selected from the group consisting of a urethane(meth)acrylate, a multifunctional (meth)acrylate and combinationsthereof.
 24. The process of claim 23, wherein the composition furthercomprises a free radical initiator.
 25. The process of claim 24, whereinthe initiator is selected from the group consisting of thermalinitiators, photoinitiators and combinations thereof.
 26. The process ofclaim 25, wherein the composition comprises a thermal initiator and aphotoinitiator, the composition being subjected to both heat andradiation at least partially cure the composition.
 27. The process ofclaim 23, wherein the portion of the wood component adjacent the secondsurface is substantially free of the (meth)acrylate composition.
 28. Theprocess of claim 23, wherein the composition further comprises astaining agent.
 29. The process of claim 23, wherein the second surfaceof the wood component is laminated to another layer.
 30. The process ofclaim 29, wherein the wood component is laminated to the another layerprior to applying the composition to the wood component.
 31. The processof claim 23, further comprising applying and curing a high performancetop coat onto the first surface after the composition is dried or atleast partially cured.
 32. The process of claim 23, further comprisingapplying a coat selected from the group consisting of a stain coat, afill coat, and a combination thereof to the first surface.
 33. Theprocess of claim 23, wherein a three roll coater is used to apply thecomposition to the first surface, the three roll coater comprising adoctor roll, an applicator roll and a wiper roll, the ratio of thesurface speed of doctor roll to the surface speed of the applicator rollbeing at least 1:5 and no more than 1:20, the wiper roll rotating in theopposite direction of the applicator roll, the ratio of the surfacespeed of the applicator roll to the surface speed of the wiper rollbeing at least 1:1.
 34. The process of claim 23, wherein the urethane(meth)acrylate is an isocyanate terminated urethane (meth)acrylate. 35.The process of claim 23, wherein the urethane (meth)acrylate or themultifunctional (meth)acrylate is a dispersion.
 36. The process of claim23, wherein the composition comprises an aliphatic urethane(meth)acrylate that reacts with free water or cellulose to form amoisture barrier.
 37. The process of claim 23, wherein the compositionfurther comprises a second (meth)acrylate.
 38. The process of claim 25,wherein the thermally activated free radical initiator is an azo orperoxide-derived thermally activated free radical initiator.
 39. Theprocess of claim 23, wherein the wood component is heated prior to theapplication of the composition.
 40. A wood flooring product comprising acomponent selected from the group consisting of first veneer layer and aplank, the component having a first surface and a second surface,wherein the portion of the component adjacent the first surfacecomprises a cured product selected from the group consisting of (a) thecured product of a hydrophilic polymer and a reactive monomer, and (b)the cured product of a (meth)acrylate selected from the group consistingof a urethane (meth)acrylate, a multifunctional (meth)acrylate andcombinations thereof, wherein the portion of the component adjacent thesecond surface is substantially free of the cured product.
 41. The woodflooring product of claim 40, wherein the portion of the componentadjacent the first surface further comprises a free radical initiator.42. The wood flooring product of claim 41, wherein the initiator isselected from the group consisting of thermal initiators,photoinitiators and combinations thereof.
 43. The wood flooring productof claim 40, wherein the portion of the component adjacent the firstsurface of the component further comprises a staining agent.
 44. Thewood flooring product of claim 40, wherein the hydrophilic polymer ispolyethylene glycol and the reactive monomer is hexanedioldimethacrylate.
 45. The wood flooring product of claim 40, wherein thecomponent is a first veneer layer and the wood flooring product furthercomprises a substrate, the second surface of the veneer layer beingadhered to the substrate.
 46. The wood flooring product of claim 45,further comprising a second veneer layer adhered to the substrateopposite the first veneer layer, the second veneer layer having a firstsurface and a second surface, the second surface of the second veneerlayer being adhered to the substrate, the portion of the second veneerlayer adjacent the first surface of the second veneer layer comprisingthe cured product.
 47. The wood flooring product of claim 46, whereinthe portion of the second veneer layer adjacent the second surface ofthe second veneer layer is substantially free of the cured product. 48.A wood flooring product comprising a component selected from the groupconsisting of first veneer layer and a plank, the component having afirst surface and a second surface, wherein the portion of the componentadjacent the first surface and the portion of the component adjacent thesecond surface comprise a cured product selected from the groupconsisting of (a) the cured product of a hydrophilic polymer and areactive monomer, and (b) the cured product of a (meth)acrylate selectedfrom the group consisting of a urethane (meth)acrylate, amultifunctional (meth)acrylate and combinations thereof, wherein theconcentration of the cured product in the portions of the componentadjacent the first surface and adjacent the second surface is at leasttwice as great as the average concentration of the cured product in thecenter portion of the component.
 49. The wood flooring product of claim48, wherein the concentration of the cured product in the portion of thecomponent adjacent the first and second surfaces is at least three timesas great as the average concentration of the cured product in the centerportion of the component.
 50. The wood flooring product of claim 49,wherein the concentration of the cured product in the portion of thecomponent adjacent the first and second surfaces is at least five timesas great as the average concentration of the cured product in the centerportion of the component.
 51. The wood flooring product of claim 48,wherein the center portion of the component is substantially free of thecured product.
 52. The wood flooring product of claim 48, wherein theportion of the component adjacent the first surface further comprises afree radical initiator.
 53. The wood flooring product of claim 52,wherein the initiator is selected from the group consisting of thermalinitiators, photoinitiators and combinations thereof.
 54. The woodflooring product of claim 48, wherein the portion of the componentadjacent the first surface of the component further comprises a stainingagent.
 55. The wood flooring product of claim 48, wherein thehydrophilic polymer is polyethylene glycol and the reactive monomer ishexanediol dimethacrylate.
 56. The wood flooring product of claim 48,wherein the component is a first veneer layer and the wood flooringproduct further comprises a substrate, the second surface of the veneerlayer being adhered to the substrate.
 57. The wood flooring product ofclaim 56, further comprising a second veneer layer adhered to thesubstrate opposite the first veneer layer, the second veneer layerhaving a first surface and a second surface, the second surface of thesecond veneer layer being adhered to the substrate, the portion of thesecond veneer layer adjacent the first surface of the second veneerlayer comprising the cured product.
 58. The wood flooring product ofclaim 57, wherein the concentration of the cured product in the portionof the veneer adjacent the first surface and adjacent the second surfaceof the veneer is at least twice as great as the average concentration ofthe cured product in the center portion of the second veneer.
 59. Thewood flooring product of claim 57, wherein the center portion of thesecond veneer is substantially free of the cured product.
 60. A woodflooring product comprising a component selected from the groupconsisting of first veneer layer and a plank, the component having afirst surface and a second surface, wherein the portion of the componentadjacent the first surface and adjacent the second surface comprises thecured product of a (meth)acrylate, the (meth)acrylate being selectedfrom the group consisting of a urethane (meth)acrylate, amultifunctional (meth)acrylate and combinations thereof.
 61. The woodflooring product of claim 60, wherein the urethane (meth)acrylate is anisocyanate terminated urethane (meth)acrylate.
 62. The wood flooringproduct of claim 60, wherein the urethane (meth)acrylate or themultifunctional (meth)acrylate is a dispersion.
 63. The wood flooringproduct of claim 60, wherein the portion of the component adjacent thefirst surface further comprises a free radical initiator.
 64. The woodflooring product of claim 63, wherein the initiator is selected from thegroup consisting of thermal initiators, photoinitiators and combinationsthereof.
 65. The wood flooring product of claim 60, wherein thecomponent is a first veneer layer and the wood flooring product furthercomprises a substrate, the second surface of the veneer layer beingadhered to the substrate.
 66. The wood flooring product of claim 65,further comprising a second veneer layer adhered to the substrateopposite the first veneer layer, the second veneer layer having a firstsurface and a second surface, the second surface of the second veneerlayer being adhered to the substrate, the portion of the second veneerlayer adjacent the first surface of the second veneer layer comprisingthe (meth)acrylate.
 67. The wood flooring product of claim 66, whereinthe portion of the second veneer layer adjacent the second surface ofthe second veneer layer is substantially free of the (meth)acrylate. 68.A wood flooring product comprising a component selected from the groupconsisting of first veneer layer and a plank, the component having afirst surface and a second surface, wherein the portions of thecomponent adjacent the first surface and adjacent the second surfacecomprise a cured product selected from the group consisting of (a) thecured product of a hydrophilic polymer and a reactive monomer, and (b)the cured product of a (meth)acrylate selected from the group consistingof a urethane (meth)acrylate, a multifunctional (meth)acrylate andcombinations thereof, wherein the component comprises less than 20grams/sq ft of the cured product.
 69. The wood flooring product of claim67, wherein the comprises less than 15 grams/sq ft of the cured product.70. The wood flooring product of claim 69, wherein the comprises lessthan 12 grams/sq ft of the cured product.